Whelen Engineering Company FLR12 User manual

Page 1
Installation Guide:
Range Light LED Floodlight
12VDC / Bail Mount / Model:FLR12
• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and procedures.
• Whelen Engineering requires the use of waterproof butt splices and/or connectors if that connector could be exposed to moisture.
• Any holes, either created or utilized by this product, should be made both air- and watertight using a sealant recommended by your vehicle
manufacturer.
• Failure to use specified installation parts and/or hardware will void the product warranty.
• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other vital parts could be damaged
by the drilling process. Check both sides of the mounting surface before drilling begins. Also de-burr the holes and remove any metal shards
or remnants. Install grommets into all wire passage holes.
• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the mounting surface with a 50/50
mix of isopropyl alcohol and water and dry thoroughly.
• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or located in the air bag deployment
area will damage or reduce the effectiveness of the air bag, or become a projectile that could cause serious personal injury or death. Refer to
your vehicle owner’s manual for the air bag deployment area. The User/Installer assumes full responsibility to determine proper mounting
location, based on providing ultimate safety to all passengers inside the vehicle.
• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be made. The recommended
procedure requires the product ground wire to be connected directly to the NEGATIVE (-) battery post (this does not include products that use
cigar power cords).
• If this product uses a remote device for activation or control, make sure that this device is located in an area that allows both the vehicle and
the device to be operated safely in any driving condition.
• Do not attempt to activate or control this device in a hazardous driving situation.
• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these lights. Do not stare directly into
these lights. Momentary blindness and/or eye damage could result.
• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking (crazing) and discoloration.
Lenses in this condition have significantly reduced effectiveness and should be replaced immediately. Inspect and operate this product
regularly to confirm its proper operation and mounting condition. Do not use a pressure washer to clean this product.
• It is recommended that these instructions be stored in a safe place and referred to when performing maintenance and/or reinstallation of this
product.
• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO THE PRODUCT OR VEHICLE
AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!
Automotive: Lightheads
Warnings to Installers
Whelen’s emergency vehicle warning devices must be properly mounted and wired in order to be effective and safe. Read and follow all of Whelen’s written
instructions when installing or using this device. Emergency vehicles are often operated under high speed stressful conditions which must be accounted for
when installing all emergency warning devices. Controls should be placed within convenient reach of the operator so that they can operate the system without
taking their eyes off the roadway. Emergency warning devices can require high electrical voltages and/or currents. Properly protect and use caution around
live electrical connections.Grounding or shorting of electrical connections can cause high current arcing, which can cause personal injury and/or vehicle
damage, including fire. Many electronic devices used in emergency vehicles can create or be affected by electromagnetic interference. Therefore, after
installation of any electronic device it is necessary to test all electronic equipment simultaneously to insure that they operate free of interference from other
components within the vehicle. Never power emergency warning equipment from the same circuit or share the same grounding circuit with radio
communication equipment. All devices should be mounted in accordance with the manufacturer’s instructions and securely fastened to vehicle elements of
sufficient strength to withstand the forces applied to the device. Driver and/or passenger air bags (SRS) will affect the way equipment should be mounted. This
device should be mounted by permanent installation and within the zones specified by the vehicle manufacturer, if any. Any device mounted in the deployment
area of an air bag will damage or reduce the effectiveness of the air bag and may damage or dislodge the device. Installer must be sure that this device, its
mounting hardware and electrical supply wiring does not interfere with the air bag or the SRS wiring or sensors. Mounting the unit inside the vehicle by a
method other than permanent installation is not recommended as unit may become dislodged during swerving; sudden braking or collision. Failure to follow
instructions can result in personal injury. Whelen assumes no liability for any loss resulting from the use of this warning device. PROPER INSTALLATION
COMBINED WITH OPERATOR TRAINING IN THE PROPER USE OF EMERGENCY WARNING DEVICES IS ESSENTIAL TO INSURE THE SAFETY OF
EMERGENCY PERSONNEL AND THE PUBLIC.
Warnings to Users
Whelen’s emergency vehicle warning devices are intended to alert other operators and pedestrians to the presence and operation of emergency vehicles and
personnel. However, the use of this or any other Whelen emergency warning device does not guarantee that you will have the right-of-way or that other
drivers and pedestrians will properly heed an emergency warning signal. Never assume you have the right-of-way. It is your responsibility to proceed safely
before entering an intersection, driving against traffic, responding at a high rate of speed, or walking on or around traffic lanes. Emergency vehicle warning
devices should be tested on a daily basis to ensure that they operate properly. When in actual use, the operator must ensure that both visual and audible
warnings are not blocked by vehicle components (i.e.: open trunks or compartment doors), people, vehicles, or other obstructions. It is the user’s responsibility
to understand and obey all laws regarding emergency warning devices. The user should be familiar with all applicable laws and regulations prior to the use of
any emergency vehicle warning device. Whelen’s audible warning devices are designed to project sound in a forward direction away from the vehicle
occupants. However, because sustained periodic exposure to loud sounds can cause hearing loss, all audible warning devices should be installed and
operated in accordance with the standards established by the National Fire Protection Association.
Safety First
This document provides all the necessary information to allow your Whelen product to be properly and safely installed. Before beginning the installation and/or
operation of your new product, the installation technician and operator must read this manual completely. Important information is contained herein that could
prevent serious injury or damage.
WARNING: This product can expose you to chemicals including Methylene Chloride which is known to the State of California to cause cancer, and
Bisphenol A, which is known to the State of California to cause birth defects or other reproductive harm. For more information go to
www.P65Warnings.ca.gov.
©2021 Whelen Aerospace Technologies
Form No. 14E04 (041421) For warranty information regarding this product, visit [e-mail]

Page 2
ASSEMBLY, SWIVEL, RANGE LIGHT
ASSEMBLY, RANGE LIGHT GSE
02-0344407-00
01-0690887-13
1
PLATE, TOP BALL/SWIVEL MT RANGE LIGHT BLACK
07-744248-023
1
SCREW, 10-24 X 3/8 PFHMS SS 100 DEG HEAD, VIBRA-TITE
14-104116-06V
2
SCREW, 10-24 X 5/8 SCKT HD CAP SS BLK OXIDE VIBRA-TITE
14-104A2C-10V
2
HANDLE, BALL MOUNT MACHINED RANGE LIGHT
08-0444249-01
1
LABEL, P/N M/N RANGE LIGHT GSE
10-0531565-00
1
ASSY, RANGE LIGHT 12V HAZE GREY CABLE 6’
01-0287112057
1
NUT, 1/4-20 ELASTIC STOP
13-130111-072
4
SCREW, 1/4-20 X 1" PFHMS SS
14-130116-160
4
WASHER, 1/4 FLAT 1/4" ID X 5/8" OD X .040 THK
16-1301820-60
4
WASHER, 1/4 SPLIT LOCK
16-1331520-65
4
SEAL, PROTECTIVE SWIVEL MOUNT
38-0144368-00
1
2
3
ITEM PART NUMBER DESCRIPTION
QTY
11
12
4
5
6
7
8
9
10
1
7
5
2
3
4
1
2-wire Range Light w/1 Switch
From
Cable From
Lighthead
WHT
BLK or
BLK/WHT
RED
BLK
4-wire Range Light w/1 Switch
BLK or BLK/WHT
BLK or BLK/WHT
WHT
WHT
BLK
From
Cable From Lighthead
GRN
WHT
RED
SW1
SW2
4-wire Range Light w/2 Switch
WHT
BLK or BLK/WHT
BLK or BLK/WHT
WHT
RED
From
Cable From Lighthead
GRN
BLK
WHT
SW1
SW2
Range Light Accessory Lenses
40° x 20° FLOOD
90° x 20° WIDE FLOOD40° x 8° WIDE FLOOD
6D481-31
6D481-336D481-32
8° SPOT
6D481-30
MFG in USA MFG in USA
MFG in USAMFG in USA
Lens #6D481-31
(40° x 20° Flood)
Lens #6D481-30 (8° Spot)
Example:
Example:
Optical Characteristics:
Projects a beam of light
having an aspect ratio
of 2:1
Optical Characteristics:
Projects a beam of light
having an aspect ratio
of 1:1 (Square)
Lens #6D481-32
(40°x 8° Wide Flood)
Lens #6D481-33
(90°x 20° Wide Flood)
Example: Example:
Optical Characteristics:
Projects a beam of light
having an aspect ratio
of 5:1
Optical Characteristics:
Projects a beam of light
having an aspect ratio
of 9:2
CAUTION: Mounting this product will require drilling. It is absolutely
necessary to make sure that no other vehicle components could be
damaged by this process. Check both sides of the mounting surface
before starting. If damage is likely, select a different mounting
location.
Mounting:
1. Position the bail bracket onto the proposed mounting surface. Mark the
areas where the mounting hole is to be drilled.
2. Drill the required mounting hole using an appropriately sized drill bit.
3. Secure the bail bracket to the mounting surface as shown using the
mounting hardware provided.
4. Insert the two brass hex nuts into the cavity provided in the rear of the
Range Light housing. Now position the Range Light housing into its
mounted position on the bail bracket. Using the hardware provided
secure the housing assembly onto the bail bracket.
5. Adjust the floodlight to the desired angle and tighten the hardware firmly
to maintain that angle.
6. Extend Range Light cable towards it’s designated power source. Make
the necessary connections using the information found in the wiring
guide.
Wiring:
Refer to the wiring guide below for wire functions, fuse values and
optional switch connections.
IMPORTANT! Before returning the vehicle to active service, visually
confirm the proper operation of this product, as well as all vehicle
components/equipment.
Lens Replacement:
1. Remove the screw and washers that secure the retainer to the Range
Light housing.
2. Remove the retainer and the lens (items 3 and 4) from the housing.
3. Before installing the new lens, make sure the gasket (item 5) is fully
seated in the housing and is not distorted, twisted or deformed in any
way.
4. Place the new lens onto the housing. Note: Be sure any text on the lens
is properly orientated. Return the retainer to its original position and
secure using the hardware removed in step 1.
Range Light:
12 VDC
35 Watts
Fuse at 5 AMPS
Wire Colors: RED: (+) BLK: (-)
Optional Switch Kits
Optional switch kits are available for Range Lights that were ordered
with the optional knuckle (for pole or pedestal mounting). Refer to the
wiring diagrams below for connectivity information.